Composite Pressure Vessel with Embedded Strain Sensor Winding
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Solution Overview
Problem
Existing strain sensors for structural health monitoring of composite material pressure vessels are limited in their ability to accurately measure strain over large areas, requiring numerous sensors and increasing costs, making commercialization difficult.
Innovation Solution
A method of manufacturing a composite material pressure vessel involves winding enamel wire strain sensors around a liner along with composite material filaments, allowing for even or concentrated distribution, and integrating a sensor module with internal pressure, temperature, and communication components to facilitate structural health monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If resistance-type strain sensors are mounted in a large number to monitor large area conditions, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent combines multiple functions into a single integrated sensor system. The strain sensor is integrated directly into the composite material structure during manufacturing, eliminating the need for separate sensor mounting processes. Multiple sensors are embedded within the composite layers, allowing simultaneous measurement across large areas without increasing external device complexity
Solution Approach 2:
The strain sensor system is designed to perform multiple functions: structural health monitoring, strain measurement, and integration with the composite material itself. The sensor serves both as a monitoring device and as part of the structural composite, reducing the need for additional dedicated monitoring components
2Measurement precision
If resistance-type strain sensors are mounted in a large number to monitor large area conditions, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The strain sensors are prepared and positioned before the final composite manufacturing steps. The sensors are pre-coated with resin and positioned on the composite surface or embedded within layers during the molding process, allowing integration without additional post-manufacturing steps or complex assembly operations
Solution Approach 2:
The sensor manufacturing process is merged with the composite material manufacturing process. Both are produced simultaneously in the same manufacturing line, eliminating the need for separate sensor installation steps and reducing overall manufacturing costs
3Measurement precision
If sensors are mounted on the pressure vessel surface, then strain measurement capability is improved, but sensor damage risk increases
Solution Approach 1:
The strain sensors are nested within the composite material structure itself. Sensors are embedded between composite layers or integrated into the composite matrix, providing physical protection from external impacts while maintaining their measurement capability. The composite structure acts as a protective envelope for the sensitive sensor elements
Solution Approach 2:
The composite material resin acts as an intermediary between the strain sensor and the external environment. The resin coating and composite layers provide mechanical protection to the sensor while allowing strain transmission, shielding the sensor from direct exposure to harsh conditions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables efficient, stable measurement of the vessel's condition, identifies damaged areas, and allows for self-diagnosis or external monitoring, reducing sensor damage and costs while ensuring accurate structural health assessment.
Implementation Method 1
enamel wire strain sensors manufactured in the form of a filament starts to be wound around the liner
Data Source
AI summary
A method of manufacturing a composite material pressure vessel is provided. The method may include preparing a liner provided with an entrance portion; and forming an inner shell by winding at least one composite material filament around the liner, wherein the forming of the inner shell includes simultaneously winding a plurality of enamel wire strain sensors around the liner together with the composite material filament by differentiating a start point where each of the plurality of enamel wire strain sensors manufactured in the form of a filament starts to be wound around the liner.A composite material pressure vessel is further manufactured by using the method.